Mitsubishi Heavy Industries S4L2-T Engine Manuals

Manuals and User Guides for Mitsubishi Heavy Industries S4L2-T Engine. We have 1 Mitsubishi Heavy Industries S4L2-T Engine manual available for free PDF download: Service Manual

Mitsubishi Heavy Industries S4L2-T Service Manual (200 pages)

Brand: Mitsubishi Heavy Industries | Category: Engine | Size: 5.59 MB

General Contents

15
- Table of Contents
  15
- General
  17
  - External View
    18
  - External View of S3L and S3L2
    18
  - External View of S4L and S4L2
    19
  - System Flow Diagrams
    20
  - Fuel System - Flow Diagram
    20
  - Lubrication System - Flow Diagram
    20
  - Cooling System - Flow Diagram
    21
  - Inlet and Exhaust System - Flow Diagram
    21
  - Engine Serial Number Location
    22
  - Specifications
    23
  - Tips on Disassembling and Reassembling
    26
  - Disassembling
    26
  - Reassembling
    26
Service Data

27
- 1 Maintenance Service Data
  
  28
  - Basic Engine
    28
  - General
    28
  - Cooling System
    31
  - Fuel System
    31
  - Inlet and Exhaust System
    31
  - Lubrication System
    31
  - Electrical System
    32
  - Basic Engines
    33
  - Fuel System
    33
  - Major Bolt Tightening Torque
    33
- 2 Tightening Torque Table
  
  33
  - Cooling System
    34
  - Electrical System
    34
  - Inlet and Exhaust Systems
    34
  - Lubrication System
    34
  - Standard Bolt and Nut Tightening Torque
    35
  - Standard Eyebolt Tightening Torque
    36
  - Standard Union Nut Tightening Torque
    36
  - Service Tools
    37
  - Determination of Overhaul
    41
  - Determining Overhaul Timing
    42
Disassembly of Basic Engine

45
- Disassembly of Basic Engine
  
  46
- 1 Disassembling and Inspecting Cylinder Head and Valve Mechanism5-2
  
  46
- 2 Disassembling and Inspecting Flywheel
  
  49
  - Removing Flywheel
    50
  - Removing Flywheel Housing
    50
  - Removing Rear Plate
    50
  - Removing Oil Seal Case
    51
- 3 Disassembling and Inspecting Gear Case, Timing Gear and Camshaft
  
  52
  - Removing Tappet
    53
  - Removing Crankshaft Pulley
    53
  - Removing Timing Gear Case
    53
  - Measuring Timing Gear Backlash
    54
  - Removing Idler Gear
    54
  - Removing Camshaft
    54
  - Removing Fuel Injection Pump Camshaft
    55
  - Removing Oil Pump
    55
  - Removing Front Plate
    55
- 4 Disassembling and Inspecting Cylinder Block, Crankshaft, Piston and Oil Pan
  
  56
  - Removing Oil Pan
    57
  - Removing Oil Strainer
    57
  - Removing Connecting Rod Cap
    57
  - Pulling out Piston
    57
  - Measuring Crankshaft End Play
    58
  - Removing Main Bearing Cap
    58
  - Removing Crankshaft
    58
  - Removing Piston Pin
    59
Inspection and Repair of Basic Engine

61
Reassembly of Basic Engine

79
- 1 Reassembling Cylinder Block, Crankshaft, Piston and Oil Pan
  
  80
  - Installing Main Bearing
    80
  - Installing Crankshaft
    80
  - Installing Main Bearing Cap
    81
  - Inserting Side Seal
    81
  - Installing Main Bearing Cap Bolt
    82
  - Measuring Crankshaft End Play
    82
  - Reassembling Piston and Connecting Rod
    83
  - Installing Piston Ring
    84
  - Installing Piston and Connecting Rod
    84
  - Installing Connecting Rod Cap
    85
  - Installing Oil Strainer
    85
  - Installing Oil Pan
    86
- 2 Reassembling Flywheel, Timing Gear and Camshaft
  
  87
  - Installing Front Plate
    87
  - Installing Oil Pump
    87
  - Rotating Crankshaft
    87
  - Installing Fuel Injection Pump Camshaft
    87
  - Installing Camshaft
    88
  - Installing Idler Gear
    88
  - Installing Timing Gear Case
    88
  - Installing Crankshaft Pulley
    89
  - Installing PTO Gear
    89
  - Installing Tappet
    89
  - Installing Oil Seal Case
    89
  - Installing Rear Plate
    90
  - Installing Flywheel Housing
    90
  - Installing Flywheel
    90
- 3 Reassembling Cylinder Head and Valve Mechanism
  
  91
Fuel System

95
- 1 Removing Fuel System
  
  96
- 2 Disassembling, Inspecting and Reassembling Fuel System
  
  99
  - Fuel Injection Nozzle
    99
  - Disassembling and Inspecting Fuel Injection Nozzle
    99
  - Reassembling Fuel Injection Nozzle
    101
  - Fuel Injection Pump
    102
  - Inspecting Fuel Injection Pump on Engine
    102
  - Disassembling and Inspecting Fuel Injection Pump
    102
  - Governor
    108
  - Disassembling and Inspecting Governor
    108
  - Inspecting Fuel Pump
    110
  - Fuel Filter
    111
  - Disassembling, Inspecting and Reassembling Fuel Filter
    111
- 3 Installing Fuel System
  
  112
  - Installing Fuel Injection Pump
    113
  - Installing Governor Weights
    113
  - Installing Sliding Sleeve
    113
  - Installing Governor Assembly
    114
  - Installing Fuel Injection Nozzle
    114
  - Installing Fuel Pipes
    114
Lubrication System

115
- 1 Removing Lubrication System
  
  116
  - Removing Oil Filter
    117
  - Removing Relief Valve
    117
  - Removing Oil Pressure Switch
    117
- 2 Disassembling, Inspecting and Reassembling Lubrication System
  
  118
  - Inspecting the Oil Pump
    118
  - Inspecting Relief Valve
    118
  - Inspecting Oil Pressure Switch
    119
- 3 Installing Lubrication System
  
  120
  - Installing Oil Pressure Switch
    121
  - Installing Relief Valve
    121
  - Installing Oil Filter
    121
Cooling System

123
- 1 Removing Cooling System
  
  124
- 2 Disassembling, Inspecting and Reassembling Cooling System
  
  125
  - Disassembling and Inspecting Thermostat10-3
    125
  - Inspecting Thermostat
    125
  - Inspecting Thermoswitch
    126
  - Inspecting Thermostat
    126
  - Inspecting Water Pump for Smooth Rotation10-4
    126
- 3 Installing Cooling System
  
  127
Inlet and Exhaust Systems

129
Electrical System

133
- 1 Removing Electrical System
  
  134
  - Removing Starter
    134
  - Inspection before Removing Alternator
    135
  - Inspecting Alternator Operation
    135
  - Handling Precaution
    135
  - Inspecting Regulated Voltage (IC Regulator Integral Type)
    136
  - Inspecting Output (a Built-In IC Regulator Type)
    136
  - Removing Alternator
    137
  - Removing Stop Solenoid
    138
  - Removing Glow Plug
    139
- 2 Disassembling, Inspecting and Reassembling Electrical System
  
  140
  - Inspection before Disassembling Starter
    140
  - No Load Test
    140
  - Disassembling and Inspecting Starter
    141
  - M008T70471A (12V-2.0Kw), M008T81071A (24V-3.2Kw)
    141
  - M001T68281(12V-1.7Kw)
    142
  - Preparation before Disassembling
    143
  - Removing Pinion Set
    143
  - Removing Magnetic Switch
    143
  - Removing Rear Bracket
    144
  - Removing Brush Holder and Brush Assembly
    144
  - Removing Armature and Yoke
    144
  - Removing Overrunning Clutch
    145
  - Removing Gear Shaft
    145
  - Inspecting and Repairing Starter
    146
  - Inspecting Brushes for Wear
    146
  - Measuring Brush Spring Load
    146
  - Inspecting Brush Holder for Insulation
    146
  - Measuring Commutator Radial Runout
    147
  - Measuring Commutator Outside Diameter12-15
    147
  - Measuring Undercut Depth
    147
  - Checking Armature Coil
    148
  - Inspecting Rear Bracket
    148
  - Inspecting Overrunning Clutch
    149
  - Inspecting Continuity of Yoke Assembly
    149
  - Inspecting Insulation between Yoke Body and Brush
    149
  - Inspecting Pinion
    150
  - Inspecting Front Bracket
    150
  - Inspecting Gears of Starter
    150
  - Inspecting Continuity of Magnetic Switch
    150
  - (Between M Terminal and Case)
    150
  - Inspecting Insulation of Magnetic Switch
    150
  - (Between M Terminal and B Terminal)
    150
  - Reassembling Starter
    151
  - Applying Grease
    152
  - Installing Pinion
    152
  - Installing Gear Shaft
    153
  - Installing Yoke and Armature
    153
  - Installing Brush Holder and Brush Assembly
    154
  - Installing Rear Bracket
    154
  - Installing Magnetic Switch
    154
  - Inspecting Pinion Clearance
    155
  - Disassembling, Inspecting and Reassembling Alternator (12V-50A)
    156
  - Separating Front Bracket from Stator
    157
  - Removing Pulley
    157
  - Removing Stator
    157
  - Inspecting Rectifier
    158
  - Inspecting Rotor
    158
  - Inspecting Stator
    159
  - Inspecting Brushes for Wear
    159
  - Replacing Brushes
    160
  - Reassembling Alternator
    160
  - Inspecting Glow Plug
    161
- 3 Installing Electrical System
  
  162
Adjustment and Operation

169
- 1 Inspection and Adjustment of Engine
  
  170
  - Inspecting Valve Clearance
    170
  - Inspecting Fuel Injection Timing
    171
  - Adjusting Fuel Injection Timing
    172
  - Inspecting and Adjusting Low Idle Speed and High Idle Speed
    173
  - Preparation
    173
  - Adjusting Low Idle Speed
    173
  - Adjusting High Idle Speed
    173
  - Bleeding Fuel System
    174
  - Bleeding Air from Fuel Filter
    174
  - Bleeding Air from Fuel Injection Pump
    174
  - Adjusting V-Belt Tension
    175
- 2 Break-In Operation
  
  176
- 3 Performance Test (JIS Standard)
  
  177
  - Engine Equipment Condition
    177
  - Test Items and Purposes
    177
  - Operation Load Test
    177
  - Continuous Load Test
    177
  - Low Idle Test
    177
  - Engine Output Adjustment
    177
  - Standard Atmospheric Conditions
    177
  - Calculation of Corrected Power
    178
Troubleshooting

179
- Troubleshooting
  180
  - Before Troubleshooting
    180
- Check Items before Troubleshooting
  181
- Problem: Starting Trouble
  181
- Starting Trouble
  181
- Check Items before Troubleshooting
  182
- Knocking
  182
- Problem: Knocking
  182
- Check Items before Troubleshooting
  183
- Overheating
  183
- Problem: Overheating
  183
- Check Items before Troubleshooting
  184
- Excessive Black Smoke
  184
- Problem: Excessive Black Smoke
  184
- Check Items before Troubleshooting
  185
- Idling Malfunction
  185
- Problem: Unstable Idling
  185
- Check Items before Troublshooting
  186
- Low Output
  186
- Problem: Low Output
  186
- Engine Inspection Sheet
  187

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Mitsubishi Heavy Industries S4L2-T Engine Manuals

Mitsubishi Heavy Industries S4L2-T Service Manual (200 pages)

Table of Contents

General Contents

Service Data

1 Maintenance Service Data

2 Tightening Torque Table

Disassembly of Basic Engine

Disassembly of Basic Engine

1 Disassembling and Inspecting Cylinder Head and Valve Mechanism5-2

2 Disassembling and Inspecting Flywheel

3 Disassembling and Inspecting Gear Case, Timing Gear and Camshaft

4 Disassembling and Inspecting Cylinder Block, Crankshaft, Piston and Oil Pan

Inspection and Repair of Basic Engine

1 Inspecting and Repairing Cylinder Head and Valve Mechanism

2 Inspecting and Repairing Flywheel

3 Inspecting and Repairing Gear Case, Timing Gear and Camshaft

4 Inspecting and Repairing Cylinder Block, Crankshaft and Piston

Reassembly of Basic Engine

1 Reassembling Cylinder Block, Crankshaft, Piston and Oil Pan

2 Reassembling Flywheel, Timing Gear and Camshaft

3 Reassembling Cylinder Head and Valve Mechanism

Fuel System

1 Removing Fuel System

2 Disassembling, Inspecting and Reassembling Fuel System

3 Installing Fuel System

Lubrication System

1 Removing Lubrication System

2 Disassembling, Inspecting and Reassembling Lubrication System

3 Installing Lubrication System

Cooling System

1 Removing Cooling System

2 Disassembling, Inspecting and Reassembling Cooling System

3 Installing Cooling System

Inlet and Exhaust Systems

1 Removing Inlet and Exhaust Systems

2 Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems

3 Installing Inlet and Exhaust Systems

Electrical System

1 Removing Electrical System

2 Disassembling, Inspecting and Reassembling Electrical System

3 Installing Electrical System

Adjustment and Operation

1 Inspection and Adjustment of Engine

2 Break-In Operation

3 Performance Test (JIS Standard)

Troubleshooting

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